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Flexible Aerogel Insulation forCoker- and Sulfur-Unit Applications
John Williams Trevor Seipp
Aspen Aerogels, Inc. Becht Engineering
Northborough, MA Calgary, AB
508-691-1137 403-256-3575jwilliams@aerogel.com tseipp@becht.com
September 13-17, 2010 - Calgary, AB, Canada
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Presentation Outline
• Product Overview
• Hot Work
• Reference Projects and Designs
• Becht Engineering Designs
• Questions
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The Aerogel Advantage:Superinsulation performance
in a flexible blanket form
What Is An Aerogel?
• Aerogels are nanoporous solids invented in the 1930’s– Aerogels are created when silica is gelled in a solvent
• When the solvent is removed, what remains is “puffed-up sand”, with up to 99% porosity
– Nanopores cage the air molecules, retarding heat flow
– Long molecular chains increase the solid path-length through the silica, reducing thermal conductivity
• Twin innovations helped move aerogels from lab curiosity to industrial product– Supercritical CO2 extraction reduces
cycle times from months to hours
– Casting the wet gel into a fibrousbatting provides mechanical integrity
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Aerogel Thermal Performance – With the Flexibility of a Blanket
• Start with a non-woven blanket– Typically polyester, glass,
carbon, or ceramic fiber
• Fill that blanket with a wet gel
• Remove the solvents via supercritical CO2 extraction
• Roll the blanket onto a spool
Step 1:Fill fibrous batting with a liquid-solidsolution
Step 2:Extract solventswith supercriticalcarbon dioxide
Step 3:Resulting dry,fiber-reinforcedaerogel blanket
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Aspen’s Aerogel Manufacturing Process
Sili
caS
ol
Cat
alys
t
Dop
ants
Rolls packedfor shipment
Dry fiberblanket
Casting
Gelation
Supercriticalextraction
Drying
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Health and Safety Aspects of Aerogels
• Aerogels are an amorphous (non-crystalline) silica with 97% of particles larger than 45m– Only the pores are nano-scale (~0.01 m)
– Aerogel particles are much larger
• Amorphous silicas have been studied by OSHA, EPA, and the OECD, concluding:– “Demonstrated lack of toxicity, mutagenicity.”
– “Is not expected to pose a carcinogenic risk.”
– “Silicas are inert when ingested, and unlikely to be absorbed through the skin.”
– “No concerns for human health.”
• Typical dust loading in fab-shop is <5 mg/m3
– OSHA limit for amorphous silica is 80 mg/m3
Aerogel (amorphous silica)
Crystalline silica
Recommended PPE is paper dust mask, work gloves, and safety glasses
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Aspen’s Industrial Products Span the Temperature Range
1200
1000
800
600
400
200
0
-200
-400-200
-100
0
100
200
300
400
500
600
°F°C Pyrogel XT (5 and 10 mm)-40°F to 1200°F (-40°C to 650°C)
Cryogel Z (5 and 10 mm)-460°F to 200°F (-273°C to 90°C)
• 2 to 3 times lower k-value than cellular glass or PUR/PIR foams
• Fast, simple installation is insensitive to workmanship or site conditions
• Excellent durability and fire resistance• Available with integral vapor barrier:
– Single-step installation– Multiple plies provide system
redundancy
• 3 to 5 times lower k-value than perlite, calcium silicate, cellular glass, or mineral/glass fiber
• Excellent productivity, especially on towers, vessels, and large pipe
• Water repellant
• Resists mechanical abuse and thermal degradation
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Aerogels Have the Lowest k-Value of Any Industrial Insulation
0
50
100
150
200
250
-200 -100 0 100 200 300 400 500 600
Temperature (°C)
Th
ermal C
on
du
ctivity (mW
/m-K
)Pyrogel XT
Perlite
Mineral WoolPipe & Board
Calsil
Cryogel Z PUR/PIR
Mineral WoolBlanket
-400 -200 0 200 400 600 800 1000 1200Temperature (°F)
Th
erm
al C
on
du
ctiv
ity
(Btu
-in
/hr-
ft2-°
F)
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
CellularglassPolystyrene
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Thickness for Equivalent Thermal Performance
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
ExpandedPerlite
CalciumSilicate
CellularGlass
MineralWool Pipe
Pyrogel Cryogel
Th
ickn
ess
for
R1
(in
)
0
2
4
6
8
10
Th
ickness fo
r R1
(mm
)
Aerogels enable thinner designs at the same level of
thermal protection
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Weight Per Unit Area for Equivalent Thermal Performance
0.0
0.1
0.2
0.3
0.4
0.5
ExpandedPerlite
CalciumSilicate
CellularGlass
MineralWool Pipe
Pyrogel XT Cryogel Z
Wei
gh
t p
er S
qu
are
Fo
ot
of
R1
(lb
)
0.0
0.5
1.0
1.5
2.0
Weig
ht p
er Sq
ua
re Me
ter of R
1 (kg)
Aerogels enable lighter designs at the same level of
thermal protection
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Pyrogel Resists the Enemies of Insulation: Water, Heat, and Abuse
Water RepellantDuring Katrina, an aerogel-
insulated pipe was flooded with sea water. Afterward, the pipeline
was drained, dried, and retested with no degradation. That pipe was then sealed, and is now in service off the coast of Africa.
Insulated space
Damage TolerantCryogel and Pyrogel easily withstand most impact or
compressive loading events (e.g., footfalls, tool strike), and will spring back to the original
performance even at loads > 100 psi. Further, because
there is no brittle failure mechanism (its a flexibleblanket), damage remains
local and will not propagate.
Thermally StableAspen Aerogel’s products do not use organic binders, so will not crumble or sag in hot service.
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Aerogels Will Not Promote Corrosion Under Insulation (CUI)
• Pyrogel and Cryogel are durably water repellent, even at high temperatures
• The open-cell nature of Aspen’s Aerogel blankets allows any water that gets around or beneath the insulation to evaporate out
• Aerogel pH is engineered to be > 7
Pyrogel is super-hydrophobic, yet also… …water vapor permeable
Water droplet withcontact angle >150°
Steam penetrates Pyrogel from kettle
underneath
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Hot Applications
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Pyrogel XT Has Many Benefits On Hot Process Equipment
MineralWool or
Fiberglass
ExpandedPerlite
CalciumSilicate
3½”
2½”
3”
Pyrogel XT
6” pipe at 600°F(315°C)
• Industry’s best k-value saves energy with 2-5X less material
– Greater space efficiency
• Installation productivity– Shop- or field fabrication– Very fast in 1 & 2 ply designs– Single-man installs– Good in difficult-access areas
• Greater in-service durability– Durably hydrophobic– Will not crack, crumble, or sag
• Reduces jacketing, banding, and vapor barrier costs
• Packed volume reduced 5-10X– Less scrap, trucking, storage
• Single part number simplifies logistics, planning
• Excellent fire protection20 mm(0.8”)
All four designs provide the same level of thermal protection
Ambient conditions = 65°F, 2 mph wind, 0.1 emissivity
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Installation of Flexible Aerogel Blankets Is Fast and Intuitive
Pyrogel blanket wraps over the pipe
Cladding & banding provide mechanical and
weather protection
Butt joints (staggered if using
multi-ply construction)
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Flat-Pack Elbows Ship Easy and Install fast
Pre-kitted “lobster tail” elbows ship flat for better packing efficiency
Multi-layer lobster tails are quickly layed up on the elbow and taped in place
Subsequent layers are installed with a
staggered joint pattern
The finished elbow is covered with a vapor barrier and jacketed with metal
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Pyrogel Enables Increased Pipe Density
Insulation Material Pyrogel Rigid Pipe Cover
20.75 in.16.25 in.2 in.
14.63 in.10.13 in.
8.38 in.5.38 in.
* Assumes 2 inch clearance space
2” Pipe: 56% more on a rack
6” Pipe: 44% more on a rack
12” Pipe: 28% more on a rack
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Aerogel Offers Simplified Inventory Management and Logistics
• Results of a trade study of a typical new-build plant insulation project…
Rigid Pipe Cover Pyrogel
Distinct Part No.’sInsulation only
28 1
Distinct Parts45:1 ratio
36,000 pieces 790 rolls
Packed Volume6:1 ratio
5700 m3 930 m3
Packed Footprint2 m stack height
53 m x 53 m 22 m x 22 m
Pyrogel can reduce the material handing and inventory management required on big jobs
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Cryogel Z and Pyrogel XTF Provide Excellent Fire Protection
0
1
2
3
4
5
0 25 50 75 100 125 150 175 200Thickness (mm)
Tim
e to
100
0°F
(h
ou
rs)
Cryogel Z
Pyrogel XTF Cellularglass
ExpandedPerlite
0 1 2 3 4 5 6 7 8Thickness (in)
UL 1709 test results based on a 10W49 I-beam:
Time-to-failure for different insulation types and
thicknesses
Calcium Silicate
Better
Worse
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Economics On 1000 m of 30” Pipe (North America)
$155$117
$122
$84
$36
$36
$150
$60
$33
$3
$15
$15
$0
$50
$100
$150
$200
$250
$300
$350
Pyrogel Calcium Silicate Mineral Wool
Tota
l In
stal
led
Co
st (
$100
0)
LogisticsOther MaterialsLaborInsulation
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Reference Projects
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Aspen Aerogels’ Products Have Been Specified Around the World
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Sulfur Tanks at Refinery in Veracruz, Mexico
• Scope: Five 24ft x ⌀105ft liquid sulfur tanks (roof and walls)
• Date: 4Q09• Process Temp: 275°F (135°C)• Design Goal: Heat conservation,
process control• Insulation: 2 layers (20 mm) of
Pyrogel XT, hung like curtains• Results:
– Before jacketing was installed, while the insulation was still bare and held on with only spray adhesive, a storm with heavy rain and 60 mph gusts blew in. Not a single piece of insulation was lost.
– Performance is in exceeding expectations.
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Coker Drums at Refinery in Lake Charles, LA
• Scope: Temporary insulation of coker drums after problems arosewith the current birdcage system
• Date: 1Q09
• Process Temp: 950°F (510°C)
• Design Goal: Heat conservation, process control
• Insulation: 3 layers (30 mm) of Pyrogel XT
• Results:– Installation labor was reduced by 60-75%
– Material continues to meet-or-beat expected thermal performance, despite exposure to the elements (the temporary nature of the install means that the weather barrier is incomplete, with many gaps)
– These “thermal band-aids” have proven so durable that Pyrogel XT is now the baseline insulation material for the next coker revamp
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Coker Feed Line at Refinery in Kuwait
• Scope: 200 ft of 12” pipe
• Date: 2Q10
• Process Temp: 930°F (500°C)
• Design Goal: Heat conservation
• Insulation: 6 layers (60 mm) of Pyrogel XT
• Results:– Owner experienced problems with
binder burnout in the previously specified mineral wool pipe cover
– Burnout lead to a loss of concentricity, which led to thermal losses, openings in the jacket, and subsequent water ingress
– Pyrogel XT uses no organic binders, and so will not sag over time
Example of loss of concentricity
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Sulfur Recovery Unit at Refinery in Torrance, CA
• Scope: 12ft x ⌀5 ft carbon bed vessel
• Date: 2Q10
• Process Temp: 60-300°F (15-150°C) cyclic
• Design Goal: Heat conservation
• Insulation: 2 layers (20 mm) of Pyrogel XT
• Results:– This vessel was particularly susceptible to
corrosion under insulation because of it’s cyclic service within the CUI zone (32-300°F)
– The previous insulation was water-absorbent and corroded out the bottom head within one year
– Pyrogel XT installed quickly with a novice insulation contractor
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Sulfur Recovery Unit Project / Maintenance in Dartmouth, NS
• Scope: Various piping and equipment
• Date: 2008-present
• Insulation: Pyrogel XT + VentureClad
• Results:– Various projects in 2008-09 were used
to benchmark aerogel productivity & cost against the baseline MW / SS spec
• A new sulfur recovery unit
• A 60’ asphalt tank (at right)
• 1200’ of 4” ET brine line
– Pyrogel XT + VentureClad was found to be cheaper on the basis of total installed cost, and provided energy, logistical, anti-CUI benefits
– Facility has since converted to 90% Pyrogel XT for maintenance and capital projects
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Towers, Vessels and Other Large Format Equipment
• The productivity advantages of blanket material vs. block is generally most pronounced on large-format piping and equipment, with labor savings approaching 80%
• Equipment and piping can also be pre-insulated, since aerogel can easily handle the rigors of shipping and erection Non-road diesel
project, Baytown, TX
Ethylene bullet, Southampton, UK
Distillation tower, Anacortes, WA
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SAGD Operation in Ft. McMurray, AB
• Scope: 3 km of 24” pipe
• Date: Summer 2009
• Process Temp.: 300°C (570°F)
• Design Goal: Heat conservation
• Other Factors: All pipingwas pre-insulated in Edmontonand trucked 6 hours to remote work site
• Results:
– Eliminated need for an on-site man camp
– Reduced effective labor rate from $200/hr to $45/hr
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Insulation Work Was Carried Out In Controlled Environment
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24” x 40ft Sections Fully Jacketed with 0.020” SE Aluminum
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Pre-Insulated Pipe Handled with Standard Equipment…
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…and Is Stacked, Ready for Shipment
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Summary and Conclusions
• Efficiency– Most efficient insulation materials in the world
– Saves energy
– Reduces touch temperatures
• Productivity– Flexible blanket form for increased productivity
– Streamlined planning, supply chain, and logistics
– Better space efficiency
– Enables pre-insulation of piping and equipment
• Durability– Resistance to damage by water, heat, and mechanical abuse
– Will not promote corrosion under insulation
– Exceptional fire protection
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Pyrogel-Enabled Coker Insulation Design from Becht Engineering
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Thank You
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